Cover and sensor for diesel exhaust fluid (def) module

ABSTRACT

A cover for a DEF assembly with openings dimensioned to receive various components that are positioned in the DEF holding tank and associated seals for closing the openings and retaining the components is disclosed. The seals are fixed to the cover by a sonic weld.

CROSS REFERENCE TO RELATED APPLICATIONS

This a Continuation of U.S. patent application Ser. No. 17/700,012 which was filed on Mar. 21, 2022 as a Divisional of U.S. patent application Ser. No. 17/206,834 which was filed on Mar. 19, 2021, and the contents of both are incorporated herein by reference as if fully set forth herein.

FIELD OF INVENTION

This disclosure generally relates to a diesel exhaust fluid (DEF) module.

BACKGROUND

Diesel exhaust fluid (DEF) is used in diesel engines in order to reduce pollution generated by the engine. DEF is typically made of a urea solution and is configured to reduce nitrogen oxides (NO_(x)) into water and nitrogen, which drastically reduces the polluting effect of the engine exhaust.

DEF tanks or modules are separate from other engine components due to urea being corrosive to metal. Additionally, DEF has a freezing point around 12° F. and therefore must be heated in order to ensure that DEF remains liquid and can be pumped from the DEF tank to the exhaust pipeline. One method of ensuring that the DEF is maintained at the proper temperature is to provide a heating element within the DEF tank. Sensor assemblies also monitor the DEF temperature and provide alerts or indications when DEF levels in the tank are low.

Due to these various requirements, it is critical that components or tubing passing thorough the cover are properly and reliably sealed.

SUMMARY

The Applicant has addressed the prior art failings with a DEF module cover assembly with a closure that has more a reliable sealing and an improved sensor assembly.

The closure has a cover portion that is dimensioned to close the DEF holding tank and includes a variety of openings for passing different components through the cover and into the DEF holding tank. A plurality of sealing devices are provided for sealing the openings according to the combination of an opening and a selected component. Each sealing device is fixed to the cover portion by a sonic weld.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing Summary and the following Detailed Description will be better understood when read in conjunction with the appended drawings, which illustrate a preferred embodiment of the disclosure. In the drawings:

FIG. 1 is a perspective view of a DEF assembly.

FIG. 2 is a partially assembled view of a module of the DEF assembly.

FIG. 3 illustrates a heating assembly attached to a cover of the module.

FIG. 4 is a magnified view of a pickup tube of the module.

FIG. 5 is a perspective view of the cover of the module taken along a cross-section through an opening defined for passage of electrical wires.

FIG. 6 is another view of the cover of FIG. 5 .

FIG. 7 is a magnified cross-sectional view of the cover in a region of the opening for the pickup tube.

FIG. 8 is a side cross-sectional view of a sensor assembly in an upper region.

FIG. 9 is a side cross-sectional view of the sensor assembly in a lower region.

FIG. 10 is a side view of the sensor assembly of FIGS. 8 and 9 .

FIG. 11 is a cross-sectional side view of the sensor assembly in the upper region.

FIG. 12 is an additional cross-sectional side view of the sensor assembly in the lower region.

DETAILED DESCRIPTION

As shown in FIGS. 1 and 2 , the DEF assembly 10 generally includes a DEF holding tank 12, a pump 14, and a cover module or closure 16. The closure 16 includes a cover 18 that forms the top of the tank 12. A pickup tube 20 is arranged within the tank 12 to provide DEF from the tank 12 to the exhaust pipeline via the pump 14.

The DEF closure 16 includes a heating assembly 30 shown in FIG. 3 . The heating assembly 30 includes a heating element 32 configured to be submerged in DEF within the tank 12. The heating assembly 30 includes a first set of electrical leads 34 a and 34 b that are connected to the heating element 32. A second set of electrical leads 36 a and 36 b, shown in FIGS. 3 and 4 , are helically wrapped around the pickup tube 20.

As shown in FIGS. 5 and 6 , the cover 18 includes a sealing assembly 40 that retains and seals multiple components passing through the cover 18. With reference to FIG. 5 , each sealing assembly includes a plug 42 dimensioned for a press-fit into an opening, such as 19 a or 19 b, in the cover 18. The plug 42 has a radially outer surface with a tapered profile that complements the radially inner surface and taper of the opening 19 a. The press-fit engagement between the tapered surfaces of the plug 42 and opening 19 a secures the plug 42 relative to the cover 18. The plug 42 may include a plurality of passages 43 a 43 b that are dimensioned to receive and secure wires, cables, or other components passing through the cover 18. The plug 42 is preferably formed from a material that is compressible, or capable of deformation. Press-fitting the plug 42 into the opening 19 a causes the plug 42 to elastically compress or deform to constrict the passages 43 a 43 b and secure the components within the plug 42. As a result of this press-fit, the need for separate clamping devises for securing a plug 42 to the cover 18 is eliminated.

As shown in FIG. 5 , the cover 18 has a shoulder or collar 21 surrounding the opening 19 a. In the preferred assembly, the plug 42 is pressed into the opening 19 a until the top surface of plug 42 is at least flush with the axial or free end of the collar 21. A sealing cap 44 is positioned over the plug 42 and the collar 21. The sealing cap 44 has lower portion 45 a that is dimensioned to surround the collar 21 and an upper portion 45 b that extends inwardly toward the center opening to extend over the plug 42. In the preferred embodiment, the sealing cap 44 is fastened to the plug 42 and the cover 18 by sonic welding them together as a unit.

With reference to FIGS. 3 and 5 through 7 , a pickup tube hose 20′ is secured to the cover 18 via a barbed hose fitting 47 and a metal clamp 48. The barbed hose fitting 47 is illustrated in FIG. 7 without the metal clamp 48. The barbed hose fitting 47 can be attached to the cover 18 by a press-fit, a sonic weld, or a threaded connection. Alternatively, the hose fitting 47 may be molded as part of the cover 18.

As shown in FIGS. 8-12 , a sensor assembly 50 is provided for the cover assembly 16. In one aspect, the sensor assembly 50 is configured to both detect a temperature of the DEF and detect a fill level of the DEF within the tank 12. As shown in FIGS. 8-12 , the housing 52 of sensor assembly 50 includes at least one sensor 76 that passes through collar 53 defined on a proximal or first end of the sensor housing 52, and extends to base of the tank 12, shown in FIG. 1 . A cap 58 closes the distal end 56 of the sensor housing 52. Preferably, the base cap 58 is sonic welded to the housing 52. A temperature sensor element 60, such as a thermistor, is preferably arranged within the sensor housing 52. At least one electrical lead 61 is connected between a power source and the temperature sensor element 60. A thermally conductive potting compound 62 is placed in opening 54 of the housing 52 to set the temperature sensor element 60. The housing 52 includes a shoulder 55 at the end opposite to cap 58 that is dimensioned to protrude through the opening 19 b when the housing connected to the cover 18.

With reference to FIGS. 8 and 10 , the junction housing 64 includes a sleeve 65 that is dimensioned to surround and engage the collar 53 of the sensor housing 52. The sensor housing 52 and the junction housing 64 are preferably fastened to each other by sonic welding. As shown in FIG. 8 , the cavity 70 inside the junction housing 64 is filled with the thermally conductive potting compound 62.

A second or free end 66 of junction housing 64 is open as a passage for the electrical lead 61 to extend out to a power source. Depending on the information being collected, multiple electrical conductors or other components can be fed out through the free end 66 of housing 64. The components passing through the free end 66 of the junction housing 64 are typically enclosed in an oil resistant wrapping or tube 74 that passes through a gasket. The free end 66 is closed with a sealing cap 68 that is dimensioned to surround the free end 66. The cap 68 is preferably sonic welded to the free end 66. 

What is claimed is:
 1. A sensor assembly for a DEF module, the sensor assembly comprising: a sensor housing having a first end that includes a shoulder with an upstanding collar, a second end, and a hollow interior; a junction housing having a first end with a sleeve that engages the upstanding collar of the sensor housing, and a second end with an opening; and, a sensor element arranged in a lower portion of the hollow interior.
 2. The sensor assembly according to claim 1, wherein the first end of the junction housing is sonic welded to the upstanding collar of the sensor housing.
 3. The sensor assembly according to claim 2, further comprising a potting compound that fills the hollow interior and surrounds the sensor element.
 4. The sensor assembly according to claim 3, wherein the potting compound at least partially fills a portion of the junction housing.
 5. The sensor assembly according to claim 1, wherein the second end of the housing is closed by a base cap.
 6. The sensor assembly according to claim 5, wherein the base cap is sonic welded to the sensor housing.
 7. The sensor assembly according to claim 1, further comprising a sealing cap that closes the opening in the second end of the junction housing.
 8. The sensor assembly according to claim 7, wherein the sealing cap is sonic welded to the junction housing.
 9. The sensor assembly according to claim 1, wherein the sensor detects temperature and fill level of diesel exhaust fluid in a tank.
 10. The sensor assembly according to claim 1, wherein the sensor is a temperature sensor.
 11. A cover assembly for a diesel exhaust fluid module, the cover assembly comprising: a cover, configured to define a top portion of the diesel exhaust fluid tank, includes at least one opening, dimensioned for passage of a lead between an exterior element and an interior of the tank, and a collar; a plug, configured to be press-fit into the at least one opening, include a passageway dimensioned for the lead to extend therethrough; and a sealing cap that engages an outer surface of the collar, and is sealed to the cover.
 12. The cover assembly according to claim 11, wherein the at least one opening has a first tapered annular surface.
 13. The cover assembly according to claim 12, wherein the plug is formed from a compressible material, whereby the at least one passageway is constricted around the lead when the plug is press-fit into the at least one opening.
 14. The cover assembly according to claim 13, wherein the plug is formed from plastic.
 15. The cover assembly according to claim 11, wherein the sealing cap is sonic welded to the cover.
 16. The cover assembly according to claim 11, wherein the plug engages directly with an annular surface of the at least one opening in the cover.
 17. The cover assembly according to claim 11, wherein the radially extending portion of the sealing cap is configured to extend radially over an interface between the collar and the plug.
 18. The cover assembly according to claim 11, wherein the cover has a second opening with a barbed fitting for connecting a pickup tube hose that extends into the tank.
 19. A method of making a sensor assembly for a diesel exhaust fluid module comprising: providing a sensor housing having a hollow opening that extends through a first end that includes a shoulder with an upstanding collar, and a second end; providing a junction housing having a first end with a sleeve dimensioned to surround and engage the upstanding collar of the sensor housing, and a second end defining an opening for passage of at least one electrical wire; providing a sensor element connected to the at least one electrical wire and arranged in a lower portion of the hollow opening; telescoping the sleeve of the junction housing over the upstanding collar of the sensor housing; and securing the first end of the junction to the upstanding collar of the sensor housing.
 20. The method of claim 19, wherein securing the first end of the junction to the upstanding collar of the sensor housing includes sonic welding.
 21. A cover assembly for a diesel exhaust fluid tank, the cover assembly comprising: a cover configured to define a top portion of the diesel exhaust fluid module includes an axially extending collar that defines at least one opening dimensioned to allow passage of an electrical wire into a diesel exhaust fluid tank; a plug that has at least one passage dimensioned to allow the electrical wire to extend into the Def tank and is configured for a press-fit into the at least one opening; a sealing cap that has: a first portion configured to engage an axially outer surface of the collar, a second portion that extends inward from the axially extending portion of the collar, and, is fastened to the cover.
 22. A sensor assembly for a diesel exhaust fluid tank, the sensor assembly comprising: a sensor housing with a central opening that extends between a diesel exhaust fluid tank's base and an open end with a surrounding shoulder; the surrounding shoulder supports an upstanding open collar; a junction housing has a first end that is mated with the upstanding open collar and a second end configured for passage of an electrical conductor associated with a sensor; a cap having a portion that encloses a gasket in abutment with the second end of the housing and a portion that engages with the second end of the housing; the cap and gasket have through passages that enable an electrical conductor associated with a sensor to extend beyond the cap; a sensor is arranged in a lower portion of the central opening with at least one electrical conductor that extends beyond the cap; and, a thermally conductive potting compound surrounds the at least one electrical conductor between the sensor and the cap.
 23. A diesel exhaust fluid tank cover and sensor assembly comprising: a cover configured for closing a diesel exhaust fluid tank; a sensor housing configured to receive a sensor between an open first end and a second end closed by a first sealing cap; a sensor positioned in a lower portion of the sensor housing toward the second end with at least one electrical lead that passes through the open first end; and, a plug, through which the at least one electrical lead passes, is positioned within an opening in the cover and secured to the cover by a second sealing cap; wherein the second sealing cap is sonic welded to the cover.
 24. The assembly of claim 23, wherein the first sealing cap is sonic welded to the sensor housing.
 25. The assembly of claim 23, wherein the first sealing cap is sonic welded to the sensor housing and the second sealing cap is sonic welded to the cover.
 26. The assembly of claim 23, wherein the at least one electrical lead is encased in potting compound. 